Manufacturing process for optical thin film with high hardness made by insert mold technology

Abstract

An optical thin film with high hardness is made by insert mold technology and manufacturing processes thereof. The optical thin film is applied on a surface of a plastic housing for increasing hardness of the plastic housing so as to prevent scratches. During manufacturing processes of the insert mold for producing a hard coating film, the step of hardening treatment is moved to the last step so as to avoid cracks on the optical thin film generated during the procedures. Thus, the yield rate is increased, and the manufacturing cost is reduced.

1. A manufacturing process for an optical thin film with high hardness made by insert mold technology comprising:
 providing an optical thin film; 
 forming a hardenable layer on the optical thin film; 
 heating the hardenable layer to a non-sticky status; 
 attaching a protective film on the optical thin film; 
 forming a figure under the optical thin film after attaching the protective film; 
 taking off the protective film after forming the figure under the optical thin film; 
 pre-forming the optical thin film and hardenable layer with heat treatment; 
 after pre-forming, injection molding a plastic material on the pre-formed optical thin film opposite to the hardenable layer; and 
 after injection molding, hardening the hardenable layer by ultraviolet (UV) light. 
 
     
     
       2. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein forming the figure under the pre-formed optical thin film comprises forming the figure as a color layer. 
     
     
       3. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein forming the figure comprises direct printing or transfer printing. 
     
     
       4. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein heating the hardenable layer comprises heating at a temperature of heating ranging from 70 Celsius degrees to 200 Celsius degrees. 
     
     
       5. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein the temperature of heating is from 100 Celsius degrees to 200 Celsius degrees. 
     
     
       6. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein heating the hardenable layer comprises heating for a time of heating ranging from 3 minutes to 120 minutes. 
     
     
       7. The manufacturing process for the optical thin film as claimed in  claim 5 , wherein the time of heating is from 5 minutes to 90 minutes. 
     
     
       8. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein forming the hardenable layer comprises slot coating, roll coating or curtain coating. 
     
     
       9. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein hardening comprises hardening by the UV light having energy output ranges from 300 mJ/cm 2  to 3000 mJ/cm 2 . 
     
     
       10. The manufacturing process for the optical thin film as claimed in  claim 1 , wherein the heat treatment includes hot stamping or thermal vacuum.